Thread: Stub axle welding procedure

Depends on what you're using the stub for, what you're attaching the stub axle to, and the size of your welder.

If you're just butt welding the stub and only have a single phase welder, then I'd grind a 10-15mm chamfer at the base of the stub and layer the weld in three passes to give you reasonable penetration. However, if the stub is used for a spare wheel bracket, then I'd cut a hole in the bumper for the stub to go through, then you can run a weld both at the bottom of the bumper/stub, and around the top of the bumper where the stub protrudes. This'll provide two points of contact and rely less on the weld alone for its strength.

If you have a three phase welder, then you can get decent penetration without having to chamfer the stub.

I'm actually fabricating front uprights for the suspension on a hill climb car i'm building. The stub will be machined round with a slight shoulder on the end and be a press fit in from the back of the upright. Still deciding if i should just fillet weld the back or do both sides.. Probably both sides. I've only got a single phase welder so i think i'll pre and post heat just to be on the safe side.